Unigas HP60, Manual Of Installation - Use - Maintenance

Page 1: ...M03957CI Rel 8 2 02 2010 BURNERS BRUCIATORI BRULERS BRENNER QUEMADORES ГОРЕЛКИ Progressive and fully modulating gas light oil burners MANUAL OF INSTALLATION USE MAINTENANCE HP60 HP65 HP72 HP73A ...

Page 2: ...ains electricity gas oil or other fuel z Observe caution with hot burner components These are usually near to the flame and the fuel pre heating system they become hot during the unit operation and will remain hot for some time after the burner has stopped When the decision is made to discontinue the use of the burner the user shall have qualified personnel carry out the following operations a Rem...

Page 3: ...of toxic or explosive mixtures DIRECTIVES AND STANDARDS Gas burners European directives Directive 90 396 CEE Gas Appliances Directive 2006 95 EC on low voltage Directive 2004 108 CEE on electromagnetic compatibility Harmonised standards UNI EN 676 Gas Burners CEI EN 60335 1 Household and similar electrical appliances Safety Part 1 General requirements EN 50165 Electrical equipment of non electric ...

Page 4: ...oil into very small particles This process is achieved making pressurised oil passing through the nozzle The pump 8 main function is to transfer oil from the tank to the nozzle in the desired quantity and pressure To adjust this pressure pumps are provided with a pressure regulator except for some models for which a separate regulating valve is provided Other pumps are provided with two pressure r...

Page 5: ...er verify the necessary input and the pressure in combustion chamber are included in the burner performance curve otherwise the choice of the burner must be revised consulting the burner manu facturer To choose the blast tube lenght follow the instructions of the boiler manufacturer In absence of these consider the following z Cast iron boilers three pass flue boilers with the first pass in the re...

Page 6: ... system maximum gas pressure switch 8 GAS CONNECTION see Specifications 40 Rp11 2 50 Rp2 65 DN65 80 DN80 BURNER TYPE HP60 0 40 HP60 0 50 HP60 0 65 Output min max kW 170 523 170 880 170 880 Fuel Natural gas Light oil Gas category see next paragraph Gas rate min max Stm3 h 18 55 18 93 18 93 Gas pressure min max mbar see Note 2 Oil train inlet pressure max bar 1 Light oil rate min max kg h 14 44 14 7...

Page 7: ...ive Fully modulating Gas Train 50 65 Valves size Gas connection 2 Rp2 2 1 2 DN65 Operating temperature C 10 50 Storage Temperature C 20 60 Working service Intermittent BURNER TYPE HP72 0 50 HP72 0 65 HP72 0 80 Output min max kW 330 1200 Fuel Nat gas Light oil Gas category see next paragraph Gas rate min max Stm3 h 35 127 Gas pressure min max mbar see Note 2 Oil train inlet pressure max bar 1 Light...

Page 8: ...tent BURNER TYPE HP73A MG x 50 HP73A MG x 65 HP73A MG x 80 Output min max kW 320 2300 Fuel Nat gas Light oil Gas category see next paragraph Gas rate min max Stm3 h 34 243 34 243 34 243 Gas pressure min max mbar see Note 2 Oil train inlet pressure max bar 1 Light oil rate min max kg h 27 194 27 194 27 194 Oil viscosity 2 7 4 cSt 40 C Oil density 840 kg m3 Power supply 230V 3 400V 3N 50Hz Total pow...

Page 9: ...C I B UNIGAS M03957CI 9 Overall dimensions mm Boiler recommended drilling template ...

Page 10: ...76 M10 330 216 250 233 465 130 335 519 x 531 198 155 HP72 MG 1 50 50 1299 139 505 373 794 382 1148 694 454 300 340 208 300 376 M10 330 216 250 233 465 130 335 519 x 531 198 155 HP72 MG 0 65 65 1299 139 505 373 794 382 1120 666 454 300 340 275 300 393 M10 330 216 250 233 533 130 403 565 313 548 198 155 HP72 MG 1 65 65 1299 139 505 373 794 382 1226 772 454 300 340 275 300 393 M10 330 216 250 233 533...

Page 11: ...e combustion head to its MIN position During the first ignition the combustion head is set in order to find a compromise between the burner output and the generator specifications that is why the minimum output may be different from the Per formance curve minimum BACK PRESSURE IN COMBUSTION CHAMBER mbar HP60 MG xx x xx A 0 40 kW HP60 MG 50 65 kW BACK PRESSURE IN COMBUSTION CHAMBER mbar HP65 MG 50 ...

Page 12: ...quoted on the y axis pressure value in the combustion chamber is not included To know the minimum pressure at the gas train inlet necessary to get the reque sted gas rate add the pressure value in the combustion chamber to the value read on the y axis 0 5 10 15 20 25 10 20 30 40 50 60 70 80 90 DN50 DN65 DN40 0 5 10 15 20 25 30 20 30 40 50 60 70 80 90 100 110 120 DN50 DN65 Rp2 50 0 10 20 30 40 20 4...

Page 13: ...e it according to the procedure described on paragraph Handling the burner 3 place the 4 stud bolts 5 on boiler s door according to the burner s drilling template described on paragraph Overall dimensions 4 fasten the 4 stud bolts 5 place the gasket on the burner flange 6 install the burner into the boiler 7 fix the burner to the stud bolts by means of the fixing nuts according to the next picture...

Page 14: ...r VPS504 gas proving system Gas train 2 Gas train with valves group VGD 20 40 with built in gas pressure governor VPS504 gas proving system Gas train 3 Gas train with valves group MBC 1200SE 2 valves gas filter pressure governor VPS504 gas proving system Gas train 4 Gas train with valves group MBC 1900 3100 5000SE 2 valves gas filter pressure governor VPS504 gas proving system 1 Burner 2 Butterfly...

Page 15: ...GS MB DLE 415 420 Mounting 1 Loosen screws A and B do not unscrew Fig 6 Fig 7 2 unscrew screws C and D Fig 6 Fig 7 3 Remove MultiBloc between the threaded flanges Fig 7 4 After mounting perform leakage and functional tests ATTENTION once the gas train is mounted according to the diagram on Fig 5 the gas proving test mus be performed according to the procedure set by the laws in force ATTENTION it ...

Page 16: ...ference gas pipe TP in figure to the gas pressure nipples placed on the gas pipe downstream the gas valves gas pres sure must be measured at a distance that must be at least 5 times the pipe size Leave the blowhole free SA in figure Should the spring fitted not permit satisfactory regulation ask one of our service centres for a suitable replacement Caution the SKP2 diaphragm D must be vertical see...

Page 17: ...onnect electrically all its elements gas valves group pressure switches gas proving system Fig 13 Fig 14 Fig 15 SIEMENS VGD MOUNTING POSITIONS Fig 16 DUNGS MBC SE Siemens SKP actuator Performance range mbar 4 20 20 40 40 80 80 150 Spring colour red black green Performance range mbar 0 22 15 120 100 250 Spring colour neutral yellow red ATTENTION once the gas train is mounted according to the diagra...

Page 18: ...plants where gravity or ring feed systems are provided install an automatic interception device see n 4 Fig 20 Fig 17 Gravity circuit Fig 18 Ring circuit Fig 19 Suction circuit Key 1 Manual valve 2 Light oil filter 3 Light oil feeding pump 4 One way valve 5 Flexible hoses 6 Relief valve ...

Page 19: ...that the by pass plug is not used in a single pipe installation because the fuel unit will not function properly and damage to the pump and burner motor could result z Do not use fuel with additives to avoid the possible formation over time of compounds which may deposit between the gear teeth thus obstructing them z After filling the tank wait before starting the burner This will give any suspend...

Page 20: ...NTEC E 1 Pressure governor 2 Pump pressure gauge 3 Inlet 4 To the nozzle 5 Return Keys SUNTEC TA 1 InletPressure governor 2 To nozzle 3 Return 4 Pressure gauge port 5 Vacuum or inlet pressure gauge port and internal by pass plug 6 Pressure adjustment 7 Preheater cavity Suntec AJ6 Viscosity 2 75 cSt Oil temperature 60 C max Inlet maximum pressure 2 bar Inlet minimum pressure 0 45 bar to avoid gasin...

Page 21: ...grams 3 check the direction of the motor see next pargraph 4 refit the panel cover Connect the three phase supply to terminals L1 L2 L3 and PE ground then shunt the phase and neutral wires Fig 22 for the auxi liaries on the printed circuit N terminal neutral L terminal phase Suntec AJ6 Suntec E Suntec TA Respect the basic safety rules make sure of the connection to the earthing system do not rever...

Page 22: ...ners are supplied for three phase 400V supply and in the case of three phase 230V supply it is necessary to modify the electrical connections into the terminal box of the electric motor and replace the overload tripped relay Fig 21 Power supply terminal board IG main switch KM1 fan motor contactor KM2 pump motor contactor MP pump motor MV fan motor TP pump motor thermal cutout TV fan motor thermal...

Page 23: ...4 Fig 26 LB Burner s lockout signalling LED LSPG Gas proving system lockout signalling LED 3 In case of modulating burners the 5 6 and 7 terminals on the MA teminal block are already connected to the regulating modula tor mod RWF40 A 4 pole plug coming out from the electrical panel is provided for the temperature and pressure probes connec tions see Fig 25 Note the regulating modulator is provided...

Page 24: ... ding to the indication on the body In the event of wrong rotation reverse the three phase supply and check again the rotation of the motor NOTE the burners are supplied for three phase 400V supply and in the case of three phase 230V supply it is necessary to modify the electrical connections into the terminal box of the electric motor and replace the overload tripped relay Fig 27 Progressive burn...

Page 25: ...ferential pressure gauge Measuring the gas pressure in the combustion head In order to measure the pressure in the combustion head insert the pressure gauge probes one into the combustion chamber s pres sure outlet Fig 30 2 to get the pressure in the combustion chamber and the other one into the butterfly valve s pressure outlet of the burner Fig 30 3 On the basis of the measured differential pres...

Page 26: ...es are achieved WARNING NEVER LOOSE THE SEALED SCREWS OTHERWISE THE DEVICE WARRANTY WILL BE IMMEDIA TELY INVALIDATE Fig 31 Keys 1 Gas filterl 2 Gas proving system 3 Gas valves 4 Fuel pump 5 Gas Adjusting cam 6 Actuator VPS504 Gas proving system The VPS504 check the operation of the seal of the gas shut off val ves This check is carried out as soon as the boiler thermostat gives a start signal to t...

Page 27: ...emperature gets too low to cause condensation in the chimney Adjustment procedure for gas operation To change the burner setting during the testing in the plant follow the next procedure On the DUNGS MBC SE gas valves group set the pressure regulator to 1 3 of its stroke using a 2 5 allen key HP73A only The burner is factory set wih the adjusting plate holes fully open and the combustion head at i...

Page 28: ...er 8 go on adjusting air and gas flow rates check continuosly the flue gas analisys as to avoid combustion with little air dose the air according to the gas flow rate change following the steps quoted below 9 acting on the pressure stabiliser of the valves group adjust the gas flow rate in the high flame stage as to meet the values requested by the boiler utilisation Multibloc MB DLE The pressure ...

Page 29: ...g cam as to reach the minimum output point 13 as for the point to point regulation move the gas low flame microswitch cam III a little lower than the maximum position 90 14 set the TAB thermostat to the minimum as far as Fully modulating burners see next paragraphs in order that the actuator moves progressively towards the low flame position 15 move cam III to the minimum to move the actuator towa...

Page 30: ...n with little air dose the air according to the gas flow rate change following the steps below acting on the pressure stabiliser of the valves group adjust the gas flow rate in the high flame stage as to meet the values requested by the boiler utilisation Multibloc MB DLE The pressure governor is adjusted by operating the screw VS located under the cover C By screwing down the pressure is increase...

Page 31: ...t again the actuator mode to MAN turn the adjusting cam and set the actuator to AUTO mode to lock the adjusting cam on the next screw adjust it and go on this way to adjust all the screws in order to set the cam foil shape accor ding to the combustion values read 16 Once the cam foil shape is defined reconnect the TAB thermostat reconnecting the wire to the terminal no 6 or setting the RWF40 burne...

Page 32: ...ssure switch when provided To calibrate the high pressure switch proceed as follows according to its mounting position 1 remove the pressure switch plastic cover 2 if the maximum pressure switch is mounted upstreaam the gas valves measure the gas pressure in the network when flame is off by means of the adjusting ring nut VR set the value read increased by the 30 3 if the maximum pressure switch i...

Page 33: ... 0 12 8 4 5 9 2 9 4 10 0 11 0 11 9 12 9 14 3 15 3 17 2 24 5 24 8 14 1 5 0 10 8 11 0 11 3 11 6 13 0 14 3 15 6 17 0 18 6 24 3 26 2 13 4 5 5 9 7 10 0 10 2 11 1 12 1 13 4 14 8 16 4 18 1 29 7 12 4 6 0 9 2 9 5 9 9 10 0 10 8 12 4 14 1 15 7 17 5 18 9 29 3 33 1 14 8 6 5 10 5 10 8 11 1 11 4 12 1 13 8 15 3 16 5 18 4 20 0 22 4 36 2 36 7 15 5 7 0 8 7 9 4 10 0 11 4 13 2 14 9 17 2 19 6 23 1 25 1 33 2 33 7 15 2 7...

Page 34: ...set the return pressure at 11bar supply at 20bar on the delivery to get a 220kg h flow rate If the return pressure needed is 5bar instead act on the V adjusting screw on the pressure governor see chapter on page 33 The flow rate will then be about 95kg h see the example showed on the Bergonzo diagram ...

Page 35: ...ans of the thermostat series and wait until the pre purge time comes to an end and that the bruner starts up 7 drive the burner to high flame stage by means fo the thermostat TAB high low flame thermostat see Wiring diagrams as far as fully modulating burners see related paragraph drive the burner to high flame stage by means fo the thermostat TAB as for fully modulating burners see next paragraph...

Page 36: ...set 20 30 more than the igni tion position Turn the burner off then start it up again If the adjustment is not correct repeat the previous steps Adjustment by the Siemens SQL33 actuator 1 Once the air and gas flow rates are adjusted turn the burner off switch the CM switch to the heavy oil operation OIL on the bur ner control panel see page 39 2 with the electrical panel open prime the oil pump ac...

Page 37: ...sting cam SV2 and set again the actuator to the AUTO mode to lock the adjusting cam 12 act on the V2 screw that mathces the bearings referring to the adjusting cam position 13 to adjust the next screw set again the actuator mode to MAN turn the adjusting cam and set the actuator to AUTO mode to lock the adjusting cam on the next screw adjust it and go on this way to adjust all the screws in order ...

Page 38: ...back nozzle is feeded at constant pressure while the return line pressure is adjusted by means of the pressure governor controlled by an actuator coupled to an adjusting cam The fuel amount to be burnt is adjusted by means of the burner actuator according to the adjustments set see prevoius paragraph Fig 42 Stand by Fig 43 Prepurge Fig 44 Low flame Fig 45 High flame Key 1 Oil pump 2 Oil solenoid v...

Page 39: ...E CAN BECOME VERY HOT AVOID TOUCHING THEM SO AS NOT TO GET BURNT OPERATION z Choose the typer of fuel by turning the A switch on the burner control panel CAUTION if the fuel chosen is light oil be sure the cutoff valves on the feed and return pipes are open z Check the control box is not locked signalling light O on if so reset it by means of the pushbutton C z Check the series of thermostats and ...

Page 40: ...r opening and when the maximum opening position is reached the pre purge time counting starts z At the end of the pre purge time the actuator is in the light oil ignition position the ignition transformer is energised lamp L on Few seconds after the light oil valves opening the transformer is de energised and lamp L turns off z The burner is now operating meanwhile the actuator goes to the high fl...

Page 41: ... and check its shape replacing the nozzle whenever a questio nable flame shape appears Whenever the burner is used intensely we recommend preventively replacing the nozzle at the start of each heating season z Clean and grease sliding and rotating parts Removing the filter in theMULTIBLOC DUNGS MB DLE 415 420 B01 1 1 2 2 z Check the filter at least once a year z Change the filter if the pressure d...

Page 42: ...8 Inspect the filter at least once a year z Change the filter if pressure value between pressure connections 1 and 2 is grea ther than 10 mbar z Change the filter if pressure value between pressure connections 1 and 2 is twice as high compared to the last inspection 1 Interrupt gas supply close ball valve 2 Remove screws 1 2 3 Replace the filter insert 3 4 Screw in screws 1 2 without use force to ...

Page 43: ...ive label for spring identification on the type plate Removing the combustion head 1 Remove the top H 2 Disconnect the electrode cables CE 3 Remove the UV detector out of its housing disconnect electrode cables and the light oil flexible hoses 4 Loosen the screws S holding the VR group screw the VR screw in order to loose the threaded rod C 5 Loosen the screws V holding the gas manifold G loosen t...

Page 44: ...ove the electrodes ass y and clean them in order to replace the electrodes unscrew the VE fixing screws and remove them place the new electrodes being careful to observe the measures in the previous paragraph reassemble the electrodes and the combustion head following the reversed procedure ATTENTION avoid the electrodes to get in touch with metallic parts blast tube head etc otherwise the boiler ...

Page 45: ...ction current follow the diagram on Fig 52 If the signal is less than the value indicated check the position of the detection electrode or detector the electrical contacts and if necessary replace the electrode or the detector Seasonal stop To stop the burner in the seasonal stop proceed as follows 1 turn the burner main switch to 0 Off position 2 disconnect the power mains 3 close the fuel valve ...

Page 46: ...AIN SWITCH OPEN z LACK OF GAS z z MAXIMUM GAS PRESSURE SWITCH DEFECTIVE IF PROVIDED z z THERMOSTATS PRESSURE SWITCHES DEFECTIVE z z z FAN MOTOR THERMAL CUTOUT INTERVENTION z OVERLOAD TRIPPED INTERVENTION z z AUXILIARY FUSES INTERRUPTED z CONTROL BOX FAULTY z z z z z DEFECTIVE ACTUATOR z z z z AIR PRESSURE SWITCH FAULT OR BAD SETTING z z z z MINIMUM GAS PRESSURE SWITCH DEFECTIVE OR GAS FILTER DIRTY...

Page 47: ...1 2 Dungs MB DLE415 21903L3 GAS VALVE GROUP Rp2 Dungs MB DLE420 21903L4 21903L4 21903L4 21903N2 GAS VALVE GROUP Rp2 Dungs MBC700SE 21903N0 21903N0 21903N0 21903N0 GAS VALVE GROUP DN65 Dungs MBC1900SE 21903M6 21903M6 21903M6 21903M6 GAS VALVE GROUP DN80 Dungs MBC3100SE 21903M7 21903M7 OIL SOLENOID VALVE 2190420 2190420 2190403 2190403 GAS PROVING SYSTEM 2191604 2191604 2191604 2191604 FLEXIBLE HOSE...

Page 48: ...53 LEVERAGE 16 NET 54 ADJUSTING CAM 17 MOTOR 55 ACTUATOR 18 PLATE 56 ACTUATOR SHAFT 19 COUPLING 57 BRACKET 20 PUMP 58 AIR INTAKE DAMPER 21 BRACKET 59 AIR INTAKE DAMPER 22 FAN WHEEL 60 AIR INTAKE 23 MOTOR 61 LOUVER SHAFT 24 PRESSURE GAUGE 62 LOUVER SHAFT 25 PRESSURE GOVERNOR 63 THROTTLE SHAFT 26 BRACKET 64 ADJUSTING CAM SHAFT 27 GAS VALVES GROUP WITH GOVERNOR 65 ADJUSTING CAM 28 THREADED GAS PIPE 6...

Page 49: ...C I B UNIGAS M03957CI 49 ...

Page 50: ... Intervention of thermal cutout signaling lamp LTA Ignition transformer in operation signaling lamp MA Burner power supply terminal board MC Burner components terminal board MP Pump motor MV Fan motor N Neutral PA Air pressure switch PGMAX Maximum gas pressure switch optional if fitted remove the connection between terminals 156 e 158 in terminal board MC PGMIN Minimum gas pressure switch PS Reset...

Page 51: ...C I B UNIGAS M03957CI 51 WIRING DIAGRAM Cod 05 680 Progressive burners ...

Page 52: ...C I B UNIGAS M03957CI 52 WIRING DIAGRAM Cod 05 681 Fully modulating burners ...

Page 53: ...ICATOR LIGHT FOR EVG 1 2 OPENING LPGMIN INDICATOR LIGHT FOR PRESENCE OF GAS IN THE NETWORK LS INDICATOR LIGHT FOR BURNER STAND BY LSPG INDICATOR LIGHT FOR LEAKAGE OF VALVES LT INDICATOR LIGHT FOR FAN OVERLOAD TRIPPED LTA IGNITION TRANSFORMER INDICATOR LIGHT MV FAN MOTOR MP LIGHT OIL PUMP MOTOR PA COMBUSTION AIR PRESSURE SWITCH PGMAX MAXIMUM PRESSURE GAS SWITCH OPTIONAL PGMIN MINIMUM GAS PRESSURE S...

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Page 57: ...in the CLOSED position and allow current to flow between terminals 11 and 8 z Any contacts checking that the fuel valve bv is closed or other con tacts with similar functions must be closed between terminal 12 and the air pressostat LP z The contact for the air pressostat LP must be in the off position LP test so as to feed terminal 4 z The gas pressostat contacts GP and the safety thermostat and ...

Page 58: ... cables normal cable laid separately 80m armoured cable high frequency protection at terminal 22 140m UV monitor Voltage in UV detector normal working 330V 10 test 380V 10 Detector current min request 70µA Max detector current normal working 630 µA test 1300 µA Max length of connecting cable normal cable laid separately 100m armoured cable high frequency protected at terminal 22 200m Weight QRA2 6...

Page 59: ...20 t6 post ventilation time t7 interval between startup consent and current created at terminal 7 t8 duration of start up t9 2nd safety time t10 interval before air pressure monitoring begins t11 damper opening travel time t12 damper closure travel time t13 permissible post combustion time t16 initial delay of damper OPEN response t20 interval before programmer automatically stops These times are ...

Page 60: ... and data subject to change Errors and omissions exceptd C I B UNIGAS S p A Via L Galvani 9 35011 Campodarsego PD ITALY Tel 39 049 9200944 Fax 39 049 9200945 9201269 web site www cibunigas it e mail cibunigas cibunigas it ...